Generac Power Systems 004916-0 User manual

Brand: Generac Power Systems

Model: 004916-0

Category: Power generators

Type: User manual

This manual is also suitable for

Quietsource 004916-0

Installation and

Owner’s Manual

Air-cooled, Prepackaged

Automatic Standby Generators

Model No. 004916-0

(10 kW NG, 11 kW LP)

DANGER

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!

Not intended for use as Primary Power in place of utility or in

life-support applications.



*This manual should

remain with the unit.

INTRODUCTION

Thank you for purchasing this model of the Quiet

Source product line by Generac Power Systems Inc.

This model is a compact, high performance, air-

cooled, engine-driven generator designed to auto-

matically supply electrical power to operate critical

loads during a utility power failure.

This unit is factory installed in an all-weather, metal

enclosure that is intended exclusively for outdoor instal-

lation. This generator will operate using either vapor

withdrawn liquid propane (LP) or natural gas (NG).

READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, contact

the nearest Authorized Dealer for starting, operating

and servicing procedures.

NOTE:

A fee may be charged if a service call is made.

Throughout this publication, and on tags and decals

affixed to the generator, DANGER, WARNING,

CAUTION and NOTE blocks are used to alert person-

nel to special instructions about a particular opera-

tion that may be hazardous if performed incorrectly

or carelessly. Observe them carefully. Their defini-

tions are as follows:

DANGER

After this heading, read instructions that, if not

strictly complied with, will result in serious person-

al injury, including death, in addition to property

damage.

After this heading, read instructions that, if not

strictly complied with, may result in serious person-

al injury or property damage.

After this heading, read instructions that, if not

strictly complied with, could result in damage to

equipment and/or property.

NOTE:

After this heading, read explanatory statements

that require special emphasis.

These safety warnings cannot eliminate the hazards

that they indicate. Common sense and strict compli-

ance with the special instructions while performing

the service are essential to preventing accidents.

Four commonly used safety symbols accompany the

DANGER, WARNING and CAUTION blocks. The type

of information each indicates follows:



This symbol points out important safety informa-

tion that, if not followed, could endanger personal

safety and/or property of others.



This symbol points out potential explosion hazard.



This symbol points out potential fire hazard.





This symbol points out potential electrical shock

hazard.

The operator is responsible for proper and safe use

of the equipment. The manufacturer strongly recom-

mends that the operator read this Owner's Manual

and thoroughly understand all instructions before

using this equipment. The manufacturer also strong-

ly recommends instructing other users to properly

start and operate the unit. This prepares them if they

need to operate the equipment in an emergency.

CONTENTS

This manual contains pertinent owner’s information,

including warranty, electrical diagrams, exploded

views and lists of repair parts, for model:

• 04916-0 – 10 kW NG, 11 kW LP, V-twin GT-990

Engine

OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety

checks, to make sure that all maintenance for safe

operation is performed promptly, and to have the

equipment checked periodically by an Authorized

Dealer. Normal maintenance service and replacement

of parts are the responsibility of the owner/operator

and, as such, are not considered defects in materials

or workmanship within the terms of the warranty.

Individual operating habits and usage contribute to

the need for maintenance service.

Proper maintenance and care of the generator ensures

a minimum number of problems and keep operating

expenses at a minimum. See an Authorized Dealer

for service aids and accessories.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs,

simply contact an Authorized Dealer for assistance.

Service technicians are factory-trained and are capa-

ble of handling all service needs.

When contacting an Authorized Dealer about parts

and service, always supply the complete model num-

ber and serial number of the unit as given on its data

decal, which is located on the generator. See Figure 1.3

for decal location.

Model No. ____________ Serial No. ______________



AUTHORIZED

DEALER LOCATION

To locate the nearest AUTHORIZED

DEALER, please call this number:

1-800-333-1322

or locate us on the web at:

www.generac.com

Table of Contents

Air-cooled 11 kW Generators

Introduction ............................... Inside Front Cover

Read This Manual Thoroughly ................................. IFC

Contents .................................................................. IFC

Operation and Maintenance ..................................... IFC

How to Obtain Service ............................................. IFC

Authorized Dealer Locator Number ............................. IFC

Safety Rules ............................................................... 2

Standards Index .................................................. 3

Section 1 – General Information .......................... 4

1.1 Unpacking/Inspection ............................................ 4

1.2 Protection Systems ................................................ 4

1.3 System Set LED .................................................... 4

1.4 Accessory Features ................................................ 4

1.4.1 12 Volt DC Outlet ...................................... 4

1.4.2 120 Volt AC Outlet .................................... 5

1.5 The Generator ....................................................... 5

1.6 Specifications ........................................................ 6

1.6.1 Generator ..................................................6

1.6.2 Engine ....................................................... 6

1.7 Fuel Requirements and Recommendations ........... 7

1.8 Fuel Consumption ................................................. 7

1.9 Reconfiguring the Fuel System .............................. 7

1.10 Location ................................................................7

1.10.1 Generator .................................................. 7

1.10.2 Transfer Switch ........................................ 8

1.11 Battery Installation ................................................ 8

1.12 The Battery ........................................................... 8

Section 2 – Post Installation Start-up

and Adjustments ................................ 9

2.1 Before Initial Startup............................................. 9

2.2 Check Transfer Switch Operation ......................... 9

2.3 Electrical Checks................................................... 9

2.4 Generator Tests Under Load ...............................10

2.5 Checking Automatic Operation ............................ 10

2.6 Voltage Regulator Adjustment .............................. 11

Section 3 – Operation ...........................................11

3.1 Break-in Procedure ............................................. 11

3.2 Using the AUTO/OFF/MANUAL Switch ................ 11

3.2.1 “Auto” Position ........................................ 11

3.2.2 “Off” Position .......................................... 12

3.2.3 “Manual” Position ....................................12

3.3 Automatic Transfer Operation ............................. 12

3.4 Sequence of Automatic Operation ....................... 12

3.5 Setting the Exercise Timer .................................. 13

3.6 Protection Systems .............................................. 13

3.6.1 Low Oil Pressure Switch ......................... 13

3.6.2 High Temperature Switch........................ 13

3.6.3 Overcrank ............................................... 13

3.6.4 Overspeed ............................................... 13

3.6.5 Low Battery ............................................. 14

Section 4 – Maintenance ...................................... 14

4.1 System Fuse ........................................................14

4.1.1 7.5 Amp Fuse .......................................... 14

4.2 Checking the Engine Oil Level ............................. 14

4.3 Changing the Engine Oil ...................................... 14

4.3.1 Engine Oil Recommendations ................. 14

4.3.2 Oil Change Procedure ............................. 15

4.4 Changing the Oil Filter ........................................ 15

4.5 Changing the Engine Air Cleaner ......................... 15

4.6 Spark Plugs .........................................................15

4.7 Battery Maintenance ............................................ 16

4.8 Adjusting GT-990 Valve Clearance ....................... 16

4.9 Cooling System.................................................... 17

4.10 Attention After Submersion ................................. 17

4.11 Corrosion Protection ........................................... 17

4.12 Out of Service Procedure ..................................... 17

4.12.1 Removal From Service ............................ 17

4.12.2 Return to Service .................................... 18

4.13 Service Schedule ................................................. 19

Section 5 – Troubleshooting ................................20

5.1 Troubleshooting Guide ........................................20

Section 6 – Installation Diagram ........................21

Section 7 – Electrical Data ...................................22

Section 8 – Exploded Views and

Parts Lists ...........................................26

Section 9 – Notes ...................................................38

Section 10 – Warranty ...........................................40

Study these SAFETY RULES carefully before install-

ing, operating or servicing this equipment. Become

familiar with this Owner’s Manual and with the

unit. The generator can operate safely, efficiently and

reliably only if it is properly installed, operated and

maintained. Many accidents are caused by failing to

follow simple and fundamental rules or precautions.

The manufacturer cannot anticipate every possible

circumstance that might involve a hazard. The warn-

ings in this manual, and on tags and decals affixed

to the unit are, therefore, not all-inclusive. If using

a procedure, work method or operating technique

the manufacturer does not specifically recommend,

ensure that it is safe for others. Also make sure the

procedure, work method or operating technique uti-

lized does not render the generator unsafe.

DANGER



Despite the safe design of this generator,

operating this equipment imprudently, neglecting

its maintenance or being careless can cause

possible injury or death. Permit only responsible

and capable persons to operate or maintain this

equipment.



Potentially lethal voltages are generated by

these machines. Ensure all steps are taken to

render the machine safe before attempting to

work on the generator.



Parts of the generator are rotating and/or hot

during operation. Exercise care near running

generators.



GENERAL HAZARDS



• For safety reasons, the manufacturer recommends

that the installation, initial start-up and main-

tenance of this equipment is carried out by an

Authorized Dealer.

• The engine exhaust fumes contain carbon monox-

ide, which can be DEADLY. This dangerous gas, if

breathed in sufficient concentrations, can cause

unconsciousness or even death. This exhaust

system must be installed properly, in strict com-

pliance with applicable codes and standards.

Following installation, do nothing that might ren-

der the system unsafe or in noncompliance with

such codes and standards.

• Keep hands, feet, clothing, etc., away from drive

belts, fans, and other moving or hot parts. Never

remove any drive belt or fan guard while the unit

is operating.

• Adequate, unobstructed flow of cooling and venti-

lating air is critical to correct generator operation.

Do not alter the installation or permit even partial

blockage of ventilation provisions, as this can seri-

ously affect safe operation of the generator. The

generator MUST be installed outdoors.

• When working on this equipment, remain alert

at all times. Never work on the equipment when

physically or mentally fatigued.

• Inspect the generator regularly, and contact the

nearest Authorized Dealer for parts needing repair

or replacement.

• Before performing any maintenance on the gen-

erator, disconnect its battery cables to prevent

accidental start up. Disconnect the cable from the

battery post indicated by a NEGATIVE, NEG or (–)

first. Reconnect that cable last.

• Never use the generator or any of its parts as a

step. Stepping on the unit can stress and break

parts, and may result in dangerous operating con-

ditions from leaking exhaust gases, fuel leakage,

oil leakage, etc.

IMPORTANT SAFETY INSTRUCTIONS

Air-cooled 11 kW Generators



SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe

operation be copied and posted near the unit’s installation site. Safety should be stressed to

all operators and potential operators of this equipment.



The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

WARNING:



This product contains or emits chemicals

known to the state of California to cause

cancer, birth defects or other reproductive harm.

WARNING:





ELECTRICAL HAZARDS



• All generators covered by this manual produce

dangerous electrical voltages and can cause fatal

electrical shock. Utility power delivers extremely

high and dangerous voltages to the transfer switch

as does the standby generator when it is in opera-

tion. Avoid contact with bare wires, terminals,

connections, etc., while the unit is running. Ensure

all appropriate covers, guards and barriers are in

place before operating the generator. If work must

be done around an operating unit, stand on an

insulated, dry surface to reduce shock hazard.

• Do not handle any kind of electrical device while

standing in water, while barefoot, or while hands or

feet are wet. DANGEROUS ELECTRICAL SHOCK

MAY RESULT.

• The National Electrical Code (NEC) requires the

frame and external electrically conductive parts of

the generator to be connected to an approved earth

ground. Local electrical codes also may require

proper grounding of the generator electrical sys-

tem.

• After installing this home standby electrical sys-

tem, the generator may crank and start at any time

without warning. When this occurs, load circuits

are transferred to the STANDBY (GENERATOR)

power source. To prevent possible injury if such a

start and transfer occur, always set the generator’s

AUTO/OFF/MANUAL switch to its OFF position

before working on equipment and remove the 7.5A

and 15A fuses from the generator control panel.

• In case of accident caused by electric shock, imme-

diately shut down the source of electrical power. If

this is not possible, attempt to free the victim from

the live conductor. AVOID DIRECT CONTACT WITH

THE VICTIM. Use a nonconducting implement,

such as a dry rope or board, to free the victim from

the live conductor. If the victim is unconscious,

apply first aid and get immediate medical help.

• Never wear jewelry when working on this equip-

ment. Jewelry can conduct electricity resulting in

electric shock, or may get caught in moving com-

ponents causing injury.



FIRE HAZARDS



• For fire safety, the generator must be installed

and maintained properly. Installation always must

comply with applicable codes, standards, laws

and regulations. Adhere strictly to local, state and

national electrical and building codes. Comply with

regulations the Occupational Safety and Health

Administration (OSHA) has established. Also,

ensure that the generator is installed in accordance

with the manufacturer’s instructions and rec-

ommendations. Following proper installation, do

nothing that might alter a safe installation and ren-

der the unit in noncompliance with the aforemen-

tioned codes, standards, laws and regulations.

• Keep a fire extinguisher near the generator at all

times. Extinguishers rated “ABC” by the National

Fire Protection Association are appropriate for

use on the standby electric system. Keep the extin-

guisher properly charged and be familiar with its

use. Consult the local fire department with any

questions pertaining to fire extinguishers.



EXPLOSION HAZARDS



• Do not smoke around the generator. Wipe up any

fuel or oil spills immediately. Ensure that no com-

bustible materials are left in the generator com-

partment, or on or near the generator, as FIRE or

EXPLOSION may result. Keep the area surround-

ing the generator clean and free from debris.

• Gaseous fluids such as natural gas and liquid pro-

pane (LP) gas are extremely EXPLOSIVE. Install

the fuel supply system according to applicable

fuel-gas codes. Before placing the home standby

electric system into service, fuel system lines must

be properly purged and leak tested according to

applicable code. After installation, inspect the fuel

system periodically for leaks. No leakage is permit-

ted.

STANDARDS INDEX

In the absence of pertinent standards, codes, regu-

lations and laws, the published information listed

below may be used as installation guide for this

equipment.

1. NFPA No. 37, STATIONARY COMBUSTION

ENGINES AND GAS TURBINES, available from

the National Fire Protection Association, 470

Atlantic Avenue, Boston, MA 02210.

2. NFPA No. 76A, ESSENTIAL ELECTRICAL

SYSTEMS FOR HEALTH CARE FACILITIES,

available same as Item 1.

3. NFPA No. 54, NATIONAL FUEL GAS CODE,

available same as Item 1.

4. NFPA No. 58, AMERICAN NATIONAL STANDARD

FOR STORAGE AND HANDLING OF LIQUEFIED

PETROLEUM GAS, available same as Item 1.

5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL

ELECTRIC CODE, available same as Item 1.

6. Article X, NATIONAL BUILDING CODE, available

from the American Insurance Association, 85

John Street, New York, N.Y. 10038.

7. AGRICULTURAL WIRING HANDBOOK, avail-

able from the Food and Energy Council, 909

University Avenue, Columbia, MO 65201.

8. ASAE EP-3634, INSTALLATION AND

MAINTENANCE OF FARM STANDBY ELECTRICAL

SYSTEMS, available from the American Society

of Agricultural Engineers, 2950 Niles Road, St.

Joseph, MI 49085.

9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE

LIQUIDS CODE, available same as Item 1.



IMPORTANT SAFETY INSTRUCTIONS

Air-cooled 11 kW Generators

DANGER



Only qualified electricians or contractors should

attempt such installations, which must comply

strictly with applicable codes, standards and

regulations.

1.1 UNPACKING/INSPECTION

After unpacking, carefully inspect the contents

for damage.

• This standby generator set has been factory sup-

plied with a weather protective enclosure that is

intended for outdoor installation only.



If this generator is used to power electrical load

circuits normally powered by a utility power

source, it is required by code to install a transfer

switch. The transfer switch must effectively iso-

late the electrical system from the utility distri-

bution system when the generator is operating

(NEC 700, 701 & 702). Failure to isolate an electri-

cal system by such means will result in damage

to the generator and also may result in injury or

death to utility power workers due to backfeed

of electrical energy.

If any loss or damage is noted at time of delivery, have

the person(s) making the delivery note all damage

on the freight bill or affix their signature under the

consignor's memo of loss or damage.

If a loss or damage is noted after delivery, separate

the damaged materials and contact the carrier for

claim procedures.

“Concealed damage” is understood to mean damage

to the contents of a package that is not in evidence at

the time of delivery, but is discovered later.

1.2 PROTECTION SYSTEMS

Unlike an automobile engine, the generator may have

to run for long periods of time with no operator pres-

ent to monitor engine conditions. For that reason, the

engine is equipped with the following systems that

protect it against potentially damaging conditions:

1. Low Oil Pressure Sensor 4. Overspeed

2. High Temperature Sensor 5. Low Battery

3. Overcrank

There are LED readouts on the control panel to notify

the user that one of these faults has occurred. There

is also a “System Set” LED that is lit when all of the

conditions describe in Section 1.3 are true.

1.3 SYSTEM SET LED

The “System Set” LED is lit when all of the following

conditions are true:

1. The AUTO/OFF/MANUAL switch is set to the

AUTO position.

2. The utility voltage being supplied to the unit is

being sensed by the PCB. If the utility sense volt-

age is not connected to the unit or if it is below

168 volts AC, then the system set light will flash

rapidly. This indicates that if the AUTO/OFF/

MANUAL switch is placed in the Auto position ,

the generator will start.

3. The “Not In Auto” dip switch is set to the OFF

position on the control board.

4. No alarms are present, for example, low oil pres-

sure, high temperature, etc.

1.4 ACCESSORY FEATURES

1.4.1 12 VOLT DC OUTLET

The generator is equipped with a 12 volt DC accesso-

ry outlet located in the system control panel (Figure

1.1). With the generator running or in standby mode,

this outlet may be used to temporarily power low

power accessories such as an inspection light, cell

phone, radio or other automotive style accessory with

a 7.5 amp maximum current draw.

Figure 1.1 — 12 Volt DC Outlet

MAN

12VD

A MAX

TLE

SSO

BREAKER

EXTERNAL

USE

TLE

USE

TIME

EXER



The 12 volt DC accessory socket is not intended

for continuous use. Power for this socket is

drawn from the engine battery. Extended use

will drain the battery and the engine may not

start. Power available at this socket is limited to

7.5 amps maximum.



Section 1 — General Information

Air-cooled 11 kW Generators

Section 1 — General Information

Air-cooled 11 kW Generators

1.5 THE GENERATOR

Exh

aust

il Filte

Oil Di

stic

Air Filt

Batter

Compartmen

ontrol Pane

ecal

Fuel Re

ulato

utle

Figure 1.3 – 11 kW, V-twin GT-990 Engine

1.4.2 120 VOLT AC OUTLET

The generator is equipped with an external, 15 amp,

120 volt, GFCI convenience outlet located on the

front of the unit (Figure 1.2). When the generator is

running, in the absence of utility power, this outlet

may be used to power items outside the home such

as lights or power tools. This outlet may also be used

when utility power is present by running the genera-

tor in manual mode.

A dedicated push-pull style circuit breaker is located

on the control panel for this outlet. Pull the breaker

stem out to open the breaker; push in to reset or

close the breaker.



Figure 1.2 — 120 Volt AC Outlet

TLE

Front View

Overhead View

Right Side View

Section 1 — General Information

Air-cooled 11 kW Generators

1.6 SPECIFICATIONS

1.6.1 GENERATOR

Model 04916-0

Rated Max. Continuous Power Capacity (Watts*) 10,000 NG/11,000 LP

Rated Voltage 120/240

Rated Max. Continuous Load Current (Amps)

120 Volts** 83.3 NG/91.7 LP

240 Volts 41.7 NG/45.8 LP

Main Line Circuit Breaker 45 Amp

Phase 1

Number of Rotor Poles 2

Rated AC Frequency 60 Hz

Power Factor 1

Recommended Air Filter Part # C8127

Battery Requirement Group 26/26R 12 Volts and

at -17.8° C (0° F) 525 Cold-cranking Amperes Minimum

Weight 495 Pounds

Output Sound Level @ 23 ft (7m) at full load 62.2 db (A)

Normal Operating Range -20°F (-28.8°C) to 104°F (40°C)

* Maximum wattage and current are subject to and limited by such factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc. Maximum power

decreases about 3.5 percent for each 1,000 feet above sea level; and also will decrease about 1 percent for each 6° C (10° F) above 16° C (60° F) ambient temperature.

** Load current values shown for 120 volts are maximum TOTAL values for two separate circuits. The maximum current in each circuit must not exceed the value stated for 240

volts.

1.6.2 ENGINE

Model 04916-0

Type of Engine GT-990

Number of Cylinders 2

Rated Horsepower 30 @ 3,600 rpm

Displacement 992cc

Cylinder Block Aluminum w/Cast Iron Sleeve

Valve Arrangement Overhead Valves

Ignition System Solid-state w/Magneto

Recommended Spark Plug RC14YC

Spark Plug Gap 0.76 mm (0.030 inch)

Compression Ratio 9.5:1

Starter 12Vdc

Oil Capacity Including Filter Approx. 1.7 Qts

Recommended Oil Filter Part # 70185

Recommended Air Filter Part # 0C8127

Operating RPM 2,700



1.7 FUEL REQUIREMENTS

AND RECOMMENDATIONS

With LP gas, use only the vapor withdrawal sys-

tem. This type of system uses the vapors formed

above the liquid fuel in the storage tank.

The engine has been fitted with a fuel carburetion

system that meets the specifications of the 1997

California Air Resources Board for tamper-proof

dual fuel systems. The unit will run on natural gas or

LP gas, but it has been factory set to run on natural

gas. Should the primary fuel need to be changed to

LP gas, the fuel system needs to be reconfigured. See

Section 1.8 for instructions on reconfiguration of the

fuel system.

Recommended fuels should have a Btu content of at

least 1,000 Btus per cubic foot for natural gas; or at

least 2,520 Btus per cubic foot for LP gas. Ask the

fuel supplier for the Btu content of the fuel.

Required fuel pressure for natural gas is 5 inches

to 7 inches water column (0.18 to 0.25); and for

liquid propane vapor, 10 inches to 12 inches of

water column (0.36 to 0.43 psi).



A seperate gas line and regulator may be need-

ed to assure proper gas pressure to the genera-

tor. Low gas pressure can cause hard starting

and could affect engine durability.

1.8 FUEL CONSUMPTION

*Natural gas is in cubic feet per hour.

**LP is in gallons per hour/cubic feet per hour.

DANGER



Gaseous fuels such as natural gas and liquid

propane (LP) gas are highly explosive. Even the

slightest spark can ignite such fuels and cause

an explosion. No leakage of fuel is permitted.

Natural gas, which is lighter than air, tends to

collect in high areas. LP gas is heavier than air

and tends to settle in low areas.

1.9 RECONFIGURING THE

FUEL SYSTEM

To reconfigure the fuel system from NG to LP,

follow these steps:

1. Turn the main gas supply off.

2. Remove the carburetor fuel hose and the brass

hose fitting from the NG (right) outlet port of the

demand regulator (Figure 1.4).

3. Remove the pipe plug from the LP (left) outlet

port.

4. Install the brass hose fitting in the LP (left) outlet

port.

5. Install the pipe plug in the NG (right) outlet

port.

6. Connect the carburetor fuel hose to the LP (left)

outlet port of the demand regulator.

7. Reverse the procedure to convert back to natural

gas.

Figure 1.4 – Demand Regulator

TLE

LP F

1.10 LOCATION

1.10.1 GENERATOR

Install the generator set, in its protective enclosure,

outdoors, where adequate cooling and ventilating air

is always available. Consider these factors:

• Install the unit where air inlet and outlet open-

ings will not become obstructed by leaves, grass,

snow, etc. If prevailing winds will cause blowing or

drifting, consider using a windbreak to protect the

unit.

• Install the generator on high ground where water

levels will not rise and endanger it.

• Allow sufficient room on all sides of the generator

for maintenance and servicing. A good rule is to

allow three feet of space on all sides.

• Where strong prevailing winds blow from one

direction, face the generator air inlet openings to

the prevailing winds.

• Install the generator as close as possible to the fuel

supply, to reduce the length of piping.

• Install the generator as close as possible to

the transfer switch. HOWEVER, REMEMBER

THAT LAWS OR CODES MAY REGULATE THE

DISTANCE.

The genset must be installed on a level surface. The

base frame must be level within two (2) inches all

around.



Section 1 — General Information

Air-cooled 11 kW Generators

Model # Nat. Gas (*) LP Vapor (**)

1/2 Load Full Load 1/2 Load Full Load

04916 115 202 1.38/55.6 2.15/86.4

1.10.2 TRANSFER SWITCH

This generator should only be installed with a com-

patible transfer switch. A range of transfer switches

are offered by the manufacturer.

1.11 BATTERY INSTALLATION



If the AUTO/OFF/MANUAL switch is not set to its

OFF position, the generator can crank and start

as soon as the battery cables are connected. If

the utility power supply is not turned off, spark-

ing can occur at the battery posts and cause an

explosion.

Fill the battery with the proper electrolyte fluid if

necessary and have the battery fully charged before

installing it.

Before installing and connecting the battery, complete

the following steps:

1. Set the generator's AUTO/OFF/MANUAL switch to

OFF.

2. Turn off utility power supply to the transfer

switch.

3. Remove the 7.5A and 15A fuses from the genera-

tor control panel.

Battery cables were factory connected at the genera-

tor (Figure 1.5). Connect cables to battery posts as

follows:

4. Connect the red battery cable (from starter con-

tactor) to the battery post indicated by a positive,

POS or (+).

5. Connect the black battery cable (from frame

ground) to the battery post indicated by a nega-

tive, NEG or (—).

NOTE:

Damage will result if battery connections are made

in reverse.

Figure 1.5 – Battery Cable Connections



NOTE:

The generator is equipped with a battery trickle

charger that is active when the unit is set up for

automatic operation. With the battery installed

and utility power source voltage available to the

transfer switch, the battery receives a trickle

charge while the engine is not running, to prevent

self-discharge. The trickle charger is designed to

help extend the life of the battery by maintain-

ing the battery when the unit is not running. The

trickle charge feature cannot be used to recharge

a discharged battery.

1.12 THE BATTERY

Servicing of the battery is to be performed or super-

vised by personnel knowledgeable of batteries and

the required precautions. Keep unauthorized person-

nel away from batteries.

When replacing the battery, use the following type of

battery: Group 26/26R 12-volt DC, negative ground

battery with a rating of 525 cold-cranking amps mini-

mum at -17.8º C (0º F). When using a maintenance-

free battery, it is not necessary to check the specific

gravity or electrolyte level. Have these procedures

performed at the intervals specified in the “Service

Schedule.” A negative ground system is used. Battery

connections are shown on the wiring diagrams. Make

sure the battery is correctly connected and terminals

are tight. Observe battery polarity when connecting

the battery to the generator set.

DANGER



Do not dispose of the battery in a fire. The

battery is capable of exploding.



A battery presents a risk of electrical shock

and high short circuit current. The following pre-

cautions are to be observed when working on

batteries:

• Remove the 7.5A and 15A fuses from the genera-

tor control panel.

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

• Do not lay tools or metal parts on top of the

battery; and

• Disconnect charging source prior to connecting or

disconnecting battery terminals.



Do not open or mutilate the battery. Released

electrolyte has been known to be harmful to the

skin and eyes, and to be toxic.



The electrolyte is a dilute sulfuric acid that is

harmful to the skin and eyes. It is electrically

conductive and corrosive.

Section 1 — General Information

Air-cooled 11 kW Generators

The following procedures are to be observed:

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off

immediately with water;

• Where electrolyte contacts the eyes, flush

thoroughly and immediately with water and seek

medical attention; and

• Spilled electrolyte is to be washed down with an

acid neutralizing agent. A common practice is to

use a solution of 1 pound (500 grams) bicarbonate

of soda to 1 gallon (4 liters) of water. The bicar-

bonate of soda solution is to be added until the

evidence of reaction (foaming) has ceased. The

resulting liquid is to be flushed with water and the

area dried.



Lead-acid batteries present a risk of fire because

they generate hydrogen gas. The

following procedures are to be followed:

• DO NOT SMOKE when near the battery;

• DO NOT cause flame or spark in battery area; and

• Discharge static electricity from body before touch-

ing the battery by first touching a grounded metal

surface.



Be sure the AUTO/OFF/MANUAL switch is set to

the OFF position before connecting the battery

cables. If the switch is set to AUTO or MANUAL,

the generator can crank and start as soon as the

battery cables are connected.



Be sure the utility power supply is turned off

and the 7.5A and 15A fuses are removed from

the generator control panel, or sparking may

occur at the battery posts as the cables are

attached and cause an explosion.

2.1 BEFORE INITIAL START-UP

Before starting, complete the following:

1. Set the generator’s main circuit breaker to its

OFF (or OPEN) position.

2. Set the generator's AUTO/OFF/MANUAL switch to

the OFF position.

3. Turn OFF the utility power supply to the transfer

switch using the means provided (such as the

utility main line circuit breaker).

4. Turn OFF all loads connected to the transfer

switch terminals T1 and T2.

5. Check the engine crankcase oil level and, if neces-

sary, fill to the dipstick FULL mark with the rec-

ommended oil. Do not fill above the FULL mark.

6. Check the fuel supply. Gaseous fuel lines must

have been properly purged and leak tested in

accordance with applicable fuel-gas codes. All

fuel shutoff valves in the fuel supply lines must be

open.



Never operate the engine with the oil level

below the “ADD” mark on the dipstick. Doing

this could damage the engine.

2.2 CHECK TRANSFER SWITCH

OPERATION

Refer to the transfer switch owner’s manual for man-

ual operation procedures.

DANGER



Do not attempt manual transfer switch opera-

tion until all power voltage supplies to the

transfer switch have been positively turned off.

Failure to turn off all power voltage supplies

will result in extremely hazardous and possibly

fatal electrical shock.

2.3 ELECTRICAL CHECKS

Complete electrical checks as follows:

1. Set the generator's main circuit breaker to its

OFF (or open) position.

2. Set the generator's AUTO/OFF/MANUAL switch to

the OFF position.

3. Turn OFF all loads connected to the transfer

switch terminals T1 and T2.

4. Turn on the utility power supply to the transfer

switch using the means provided (such as a utility

main line circuit breaker).

DANGER



The transfer switch is now electrically “hot.”

Contact with “hot” parts will result in extremely

hazardous and possibly fatal electrical shock.

Proceed with caution.

5. Use an accurate AC voltmeter to check utility

power source voltage across transfer switch ter-

minals N1 and N2. Nominal line-to-line voltage

should be 240 volts AC.

6. Check utility power source voltage across termi-

nals N1 and the transfer switch neutral lug; then

across terminal N2 and neutral. Nominal line-to-

neutral voltage should be 120 volts AC.

7. When certain that utility supply voltage is compat-

ible with transfer switch and load circuit ratings,

turn OFF the utility power supply to the transfer

switch.

8. On the generator panel, set the AUTO/OFF/

MANUAL switch to MANUAL. The engine should

crank and start.

9. Let the engine warm up for about five minutes to

allow internal temperatures to stabilize. Then, set

the generator’s main circuit breaker to its ON (or

closed) position.

Section 2 — Post Installation Start-up and Adjustments

Air-cooled 11 kW Generators

DANGER



Proceed with caution! Generator power voltage

is now supplied to the transfer switch. Contact

with live transfer switch parts will result in dan-

gerous and possibly fatal electrical shock.

10. Connect an accurate AC voltmeter and a fre-

quency meter across transfer switch terminal

lugs E1 and E2. Voltage should be 242-252 volts;

frequency should read about 61-63 Hertz.

11. Connect the AC voltmeter test leads across ter-

minal lug E1 and neutral; then across E2 and

neutral. In both cases, voltage reading should be

121-126 volts AC.

12. Set the generator’s main circuit breaker to its

OFF (or open) position. Let the engine run at no-

load for a few minutes to stabilize internal engine

generator temperatures.

13. Set the generator's AUTO/OFF/MANUAL switch to

OFF. The engine should shut down.

NOTE:

It is important not to proceed until certain that

generator AC voltage and frequency are correct

and within the stated limits. Generally, if both AC

frequency and voltage are high or low, the engine

governor requires adjustment. If frequency is cor-

rect, but voltage is high or low, the generator’s

voltage regulator requires adjustment.

2.4 GENERATOR TESTS UNDER LOAD

To test the generator set with electrical loads applied,

proceed as follows:

1. Set generator’s main circuit breaker to its OFF

(or open) position.

2. Turn OFF all loads connected to the transfer

switch terminals T1 and T2.

3. Set the generator's AUTO/OFF/MANUAL switch to

OFF.

4. Turn OFF the utility power supply to the transfer

switch, using the means provided (such as a util-

ity main line circuit breaker).



Do not attempt manual transfer switch opera-

tion until all power voltage supplies to the

transfer switch have been positively turned off.

Failure to turn off all power voltage supplies

will result in extremely hazardous and possibly

fatal electrical shock.

5. Manually set the transfer switch to the STANDBY

position, e.g., load terminals connected to the

generator's E1/E2 terminals. The transfer switch

operating lever should be down.

6. Set the generator's AUTO/OFF/MANUAL switch

to MANUAL. The engine should crank and start

immediately.

7. Let the engine stabilize and warm up for a few

minutes.

8. Set the generator’s main circuit breaker to its ON

(or closed) position. Loads are now powered by

the standby generator.

9. Turn ON electrical loads connected to transfer

switch T1 and T2. Apply an electrical load equal

to the full rated wattage/amperage capacity of the

installed generator.

10. Connect an accurate AC voltmeter and a frequen-

cy meter across terminal lugs E1 and E2. Voltage

should be greater than 230 volts; frequency

should be greater than 58 Hertz.

11. Let the generator run at full rated load for 20-30

minutes. Listen for unusual noises, vibration or

other indications of abnormal operation. Check

for oil leaks, evidence of overheating, etc.

12. When testing under load is complete, turn OFF

electrical loads.

13. Set the generator's main circuit breaker to its

OFF (or open) position.

14. Let the engine run at no-load for a few minutes.

15. Set the AUTO/OFF/MANUAL switch to OFF. The

engine should shut down.

2.5 CHECKING AUTOMATIC

OPERATION

To check the system for proper automatic operation,

proceed as follows:

1. Set generator’s main circuit breaker to its OFF

(or open) position.

2. Check that the AUTO/OFF/MANUAL switch is set

to OFF.

3. Turn OFF the utility power supply to the transfer

switch, using means provided (such as a utility

main line circuit breaker).

4. Manually set the transfer switch to the UTILITY

position, i.e., load terminals connected to the util-

ity power source side.

5. Turn ON the utility power supply to the transfer

switch, using the means provided (such as a util-

ity main line circuit breaker).

6. Set the AUTO/OFF/MANUAL switch to AUTO. The

system is now ready for automatic operation.

7. Turn OFF the utility power supply to the transfer

switch.

With the AUTO/OFF/MANUAL switch at AUTO, the

engine should crank and start when the utility source

power is turned OFF. After starting, the transfer

switch should connect load circuits to the standby

side. Let the system go through its entire automatic

sequence of operation.

Section 2 — Post Installation Start-up and Adjustments

Air-cooled 11 kW Generators

With the generator running and loads powered by

generator AC output, turn ON the utility power supply

to the transfer switch. The following should occur:

• After about six seconds, the switch should transfer

loads back to the utility power source.

• About one minute after retransfer, the engine

should shut down.

2.6 VOLTAGE REGULATOR

ADJUSTMENT

With the frequency between 60-60.5 Hertz, slowly

turn the slotted potentiometer (Figure 2.1) until line

voltage reads 247-252 volts.

NOTE:

The access panel on top of the control panel must

be removed to adjust the voltage regulator.

Figure 2.1 – Voltage Adjustment Potentiometer

NOTE:

The voltage regulator is housed inside the gen-

erator's control panel. The regulator maintains a

voltage in direct proportion to frequency at a 2-to-

1 ratio. For example, at 62 Hertz, line-to-neutral

voltage will be 124 volts.

3.1 BREAK-IN PROCEDURE

Once the unit has been installed and all electrical

checks have been made, it is strongly recommended

that the following “Break-in Procedure” be completed

to ensure correct generator operation in the future.

1. Set the generator’s AUTO/OFF/MANUAL switch to

AUTO.

2. Turn OFF the utility power supply to the transfer

switch using the means provided (such as a utility

main line circuit breaker).

3. The unit will start, and the transfer switch will

transfer to standby.

4. Run the unit for one hour at 25% rated load.

5. Run the unit for one hour at 50% rated load.

6. Run the unit for one hour at 75% rated load.

7. Run the unit for one hour at 100% rated load.

8. Turn ON the utility power supply to the transfer

switch, which will allow the transfer switch to

transfer back to utility power. The unit will con-

tinue to run for one minute and then shut down.

9. Allow the unit to cool.

10. Set the generator's AUTO/OFF/MANUAL switch

to OFF. Remove the 7.5A and 15A fuses from the

generator control panel. Disconnect the battery

cables as outlined in “General Hazards” (page

2).

11. Drain the oil and remove the oil filter. Replace

the oil filter according to Section 4.4, “Changing

the Oil Filter”. Replace the oil with synthetic oil

as recommended in Section 4.3, “Changing the

Engine Oil”.

12. Reconnect the battery cables as outlined in

“General Hazards” (page 2) and insert the 5A and

15A fuses into the generator control panel. The

generator is now ready for service.

3.2 USING THE AUTO/OFF/MANUAL

SWITCH (FIGURE 3.1)

3.2.1 “AUTO” POSITION

Selecting this switch position activates fully automat-

ic system operation. It also allows personnel to start

and exercise the engine every seven days with the set-

ting of the exercise timer (see Section 3.5).

Figure 3.1 – Generator Control Panel



Section 3 — Operation

Air-cooled 11 kW Generators

3.2.2 “OFF” POSITION

This switch position shuts down the engine. This

position also prevents automatic operation.

3.2.3 “MANUAL” POSITION

Set the switch to Manual to crank and start the

engine. Transfer to standby power will not occur

unless there is a utility failure.



With the switch set to AUTO, the engine may

crank and start at any time without warning.

Such automatic starting normally occurs when

utility power source voltage drops below a pre-

set level or during the normal exercise cycle. To

prevent possible injury that might be caused

by such sudden starts, always set the switch to

OFF and remove the fuses before working on or

around the generator or transfer switch. Then,

place a “DO NOT OPERATE” tag on the generator

panel and on the transfer switch.

3.3 AUTOMATIC TRANSFER

OPERATION

To select automatic operation, do the following:

1. Make sure the transfer switch main contacts are

set to their “Utility” position, i.e., loads connected

to the utility power source (Figure 3.2).

2. Be sure that normal utility power source voltage

is available to transfer switch terminal lugs N1

and N2.

3. Set the generator’s AUTO/OFF/MANUAL switch to

AUTO.

4. Set the generator’s main circuit breaker to its ON

(or closed) position.

With the preceding steps complete, the generator will

start automatically when utility source voltage drops

below a preset level. After the unit starts, loads are

transferred to the standby power source. Refer to

Section 3.4, “Sequence of Automatic Operation.”



3.4 SEQUENCE OF AUTOMATIC

OPERATION

The generator’s control panel houses a control logic

circuit board. This board constantly monitors util-

ity power source voltage. Should that voltage drop

below a preset level, circuit board action will signal

the engine to crank and start. After the engine starts,

the circuit board signals the transfer switch to acti-

vate and connect load circuits to the standby power

supply (load terminal lugs T1/T2 connect to terminal

lugs E1/E2).

Upon restoration of utility source voltage above a

preset level, generator circuit board action signals the

transfer switch to transfer loads back to that power

supply. After retransfer, the engine is signalled to shut

down.

The actual sequence of operation is controlled by

sensors and timers on a control logic circuit board,

as follows:

A. Utility Voltage Dropout Sensor

• This sensor monitors utility source voltage.

• If utility source voltage drops below about 70

percent of the nominal supply voltage, the sensor

energizes a 15-second timer.

• Once the timer has expired, the engine will crank

and start.

B. Engine Warm-up Time Delay

• This mechanism lets the engine warm up for

about 10 seconds before the load is transferred

to the standby source.

C. Utility Voltage Pickup Sensor

• This sensor monitors utility power supply volt-

age. When that voltage is restored above 70 per-

cent of the nominal source voltage, a retransfer

time delay starts timing.

D. Retransfer Time Delay

• This timer runs for about 15 seconds.

• At end of a 15-second delay, circuit board

action de-energizes transfer relay in the transfer

switch.

• Retransfer to utility power source then occurs.

E. Engine Cool-down Timer

• When the load is transferred back to utility power

source, the engine cool-down timer starts tim-

ing.

• The timer will run for about one minute, and the

generator will then shut down.

Section 3 — Operation

Air-cooled 11 kW Generators

Section 3 — Operation

Air-cooled 11 kW Generators

3.5 SETTING THE EXERCISE TIMER

This generator is equipped with an exercise timer.

Once it is set, the generator will start and exercise

once every seven days, on the day of the week and at

the time of day the following sequence is completed.

During this exercise period, the unit runs for approx-

imately 12 minutes and then shuts down. Transfer of

loads to the generator output does not occur during

the exercise cycle.

A switch on the control panel (see Figure 3.1) per-

mits selection of the day and time for the system to

exercise. At the chosen time, perform the following

sequence to select the desired day and time of day the

system will exercise.

Place the AUTO/OFF/MANUAL switch in the AUTO

position. Push and hold the “Set Exercise Time”

switch to the ON position for approximately three

seconds and release. All five red LED’s will flash for

10 seconds. The unit will perform the standard exer-

cise sequence, then shut down. The generator will

now exercise every seven days at the time set.

NOTE:

The exerciser will only work in the AUTO mode

and will not work unless this procedure is per-

formed. The exerciser will need to be reset every

time the 12-volt battery is disconnected and then

reconnected.

3.6 PROTECTION SYSTEMS

3.6.1 LOW OIL PRESSURE SWITCH

This switch (Figure 3.2) has normally closed con-

tacts that are held open by engine oil pressure dur-

ing cranking and operating. Should oil pressure

drop below the 8 psi range, switch contacts close,

and the engine shuts down. The unit should not be

restarted until oil is added. The AUTO/OFF/MANUAL

switch must then be turned to OFF and then back to

AUTO.

3.6.2 HIGH TEMPERATURE SWITCH

This switch’s contacts (Figure 3.3) close if the tem-

perature should exceed approximately 132º C (270º

F), initiating an engine shutdown. The generator will

automatically restart and the LED on the generator

control panel will reset once the temperature has

returned to a safe operating level.



Figure 3.2 – Low Oil Pressure and

High Temperature Switches

3.6.3 OVERCRANK

This feature prevents the generator from damaging

itself when it continually attempts to start and anoth-

er problem, such as no fuel supply, prevents it from

starting. The unit will crank and rest for a preset

time limit. Then, it will stop cranking, and the LED

on the generator control panel will light indicating an

overcrank failure. The AUTO/OFF/MANUAL switch

will need to be set to OFF and then back to AUTO to

reset the generator control board.

NOTE:

If the fault is not repaired, the overcrank feature

will continue to activate.

3.6.3.1 Approximate Crank Cycle Times

• 15 seconds ON

• 7 seconds OFF

• 7 seconds ON

• 7 seconds OFF

• Repeat for 45 seconds

Approximately 90 seconds total

3.6.4 OVERSPEED

This feature protects the generator from damage by

shutting it down if it happens to run faster than the

preset limit. This protection also prevents the gen-

erator from supplying an output that could poten-

tially damage appliances connected to the generator

circuit. Contact the nearest Authorized Dealer if this

failure occurs.



Section 4 — Maintenance

Air-cooled 11 kW Generators

3.6.5 LOW BATTERY

The microprocessor will continually monitor the bat-

tery voltage and turn on the Low Battery LED if the

battery voltage falls below 11.0 volts for one minute.

Low battery voltage is a non-latching alarm, which

will automatically clear if the battery voltage rises

above 11.0 volts.

The control system will not attempt to start the

engine if there is a low battery condition, however,

if the engine is already running when the low bat-

tery condition occurs, the engine will continue to

run as long as possible.

Battery voltage is NOT monitored during the crank

cycle.

4.1 SYSTEM FUSE

The generator panel’s 15 amp fuse (Figure 4.1) pro-

tects the DC control circuit against overload. The fuse

is wired in series with the battery output lead to the

panel. If the fuse element has melted open, the engine

cannot crank or start. Replace the fuse using only an

identical 15-amp replacement.

4.1.1 7.5 AMP FUSE

The generator panel’s 7.5 amp fuse protects the

accessory outlet against overload. If the fuse element

has melted open, there will not be power at the acces-

sory outlet. Replace the fuse using only an identical

7.5 amp fuse. To remove fuse, push cap down and

rotate counterclockwise.

Figure 4.1 – Generator Control Panel



4.2 CHECKING THE ENGINE

OIL LEVEL

For oil capacities, see “Specifications,” Section 1.5.

For engine oil recommendations, see Section 4.3.1.

To check the engine oil level, proceed as follows

(Figures 4.2):

1. Start the generator by moving the AUTO/ OFF/

MANUAL switch to the MANUAL position. Allow

it to run for a short while and then shut it down

by moving the switch to the OFF position.

2. Remove the dipstick and wipe it dry with a

clean cloth.

3. Install the dipstick; then, remove it again. The oil

level should be at the dipstick “Full” mark. If nec-

essary, add oil to the “Full” mark only. DO NOT

FILL ABOVE THE “FULL” MARK.



Never operate the engine with the oil level

below the “Add” mark on the dipstick. Doing

this could damage the engine.

4. Install the dipstick.

5. Reset the AUTO/OFF/MANUAL switch to its origi-

nal position.

Figure 4.2 — Oil Dipstick and Fill

Oil Di

stic

il Fil

4.3 CHANGING THE ENGINE OIL

4.3.1 ENGINE OIL RECOMMENDATIONS

Use oil of American Petroleum Institute (API) Service

Class SG, SH or SJ. Use all season SAE 5W-30

Synthetic oil. Organic break-in oil is required before

using synthetic oil.

NOTE:

The unit is supplied with “break-in” oil. See the

“Break-in Procedure,” Section 3.1, for the first

required oil change.



Section 4 — Maintenance

Air-cooled 11 kW Generators



Any attempt to crank or start the engine before

it has been properly serviced with the recom-

mended oil may result in an engine failure.

4.3.2 OIL CHANGE PROCEDURE

To change the oil, proceed as follows:

1. Run the engine until it is thoroughly warmed up

then shut OFF the engine.

2. Immediately after the engine shuts OFF, pull the

oil drain hose (Figure 4.3) free of its retaining

clip. Remove the cap from the hose and drain the

oil into a suitable container.

3. After the oil has drained, replace the cap onto the

end of the oil drain hose. Retain the hose in the

clip.

4. Refill with the proper recommended oil (see

Section 4.3.1). See Section 1.6.2 for oil capaci-

ties.

Figure 4.3 – Oil Drain Hose and Filter

il Filte

il Drain Hos

4.4 CHANGING THE OIL FILTER

Change the engine oil filter as follows:

1. With the oil drained, remove the old oil filter by

turning it counterclockwise.

2. Apply a light coating of clean engine oil to the

gasket of the new filter. See Section 1.6.1 for rec-

ommended filter.

3. Screw the new filter on by hand until its gasket

lightly contacts the oil filter adapter. Then, tighten

the filter an additional 3/4 to one turn (Figure

4.3).

4. Refill with the proper recommended oil (see

Section 4.3.1). See Section 1.6.2 for oil capaci-

ties.

5. Start the engine and check for leaks.



4.5 CHANGING THE ENGINE

AIR CLEANER

See Figure 1.3, for the location of the air cleaner. Use

the following procedure (Figure 4.4):

1. Turn the two screws counterclockwise to loosen.

2. Remove the cover and air filter.

3. Wipe away dust or debris from inside of the air

box and around edges.

4. Install the new air cleaner into the air box.

5. Install the cover. Turn the two cover screws clock-

wise to tighten.

See the “Service Schedule,” Section 4.13, for air

cleaner maintenance. See Section 1.6.1 for air filter

replacement part number.

Figure 4.4 — Engine Air Cleaner

cre

ove

Filt

4.6 SPARK PLUGS

Reset the spark plug gaps or replace the spark plugs

as necessary. See Section 4.13 for maintenance

requirements.

1. Clean the area around the base of the spark plugs

to keep dirt and debris out of the engine. Clean

by scraping or washing using a wire brush and

commercial solvent. Do not blast the spark plugs

to clean.

2. Remove the spark plugs and check the condition.

Replace the spark plugs if worn or if reuse is

questionable. See Section 4.13 for recommended

inspection.

3. Check the spark plug gap using a wire feeler

gauge. Adjust the gap to 0.76 mm (0.030 inch)

by carefully bending the ground electrode (Figure

4.5).

Loosen

Section 4 — Maintenance

Air-cooled 11 kW Generators

Figure 4.5 – Setting the Spark Plug Gap

4.7 BATTERY MAINTENANCE

The battery should be inspected per the “Service

Schedule,” Section 4.13. The following procedure

should be followed for inspection:

1. Inspect the battery posts and cables for tightness

and corrosion. Tighten and clean as necessary.

2. Check the battery fluid level of unsealed batteries

and, if necessary, fill with Distilled Water Only. Do

not use tap water in batteries.

3. Have the state of charge and condition checked.

This should be done with an automotive-type bat-

tery hydrometer.

DANGER



Do not dispose of the battery in a fire. The

battery is capable of exploding.



A battery presents a risk of electrical shock

and high short circuit current. The following pre-

cautions are to be observed when working on

batteries:

• Remove the 7.5A and 15A fuses from the genera-

tor control panel.

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

• Do not lay tools or metal parts on top of the

battery; and

• Disconnect charging source prior to connecting or

disconnecting battery terminals.



Do not open or mutilate the battery. Released

electrolyte has been known to be harmful to the

skin and eyes, and to be toxic.



The electrolyte is a dilute sulfuric acid that is

harmful to the skin and eyes. It is electrically

conductive and corrosive. The following

procedures are to be observed:

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off

immediately with water;

• Where electrolyte contacts the eyes, flush

thoroughly and immediately with water and seek

medical attention; and

• Spilled electrolyte is to be washed down with an

acid neutralizing agent. A common practice is to

use a solution of 1 pound (500 grams) bicarbonate

of soda to 1 gallon (4 liters) of water. The bicar-

bonate of soda solution is to be added until the

evidence of reaction (foaming) has ceased. The

resulting liquid is to be flushed with water and the

area dried.



Lead-acid batteries present a risk of fire because

they generate hydrogen gas. The

following procedures are to be followed:

• DO NOT SMOKE when near the battery;

• DO NOT cause flame or spark in battery area; and

• Discharge static electricity from body before touch-

ing the battery by first touching a grounded metal

surface.



Be sure the AUTO/OFF/MANUAL switch is set to

the OFF position before connecting the battery

cables. If the switch is set to AUTO or MANUAL,

the generator can crank and start as soon as the

battery cables are connected.



Be sure the utility power supply is turned off

and the 5A and 15A fuses are removed from the

generator control panel, or sparking may occur

at the battery posts as the cables are attached

and cause an explosion.

4.8 ADJUSTING GT-990 VALVE

CLEARANCE

After the first six months of operation, adjust the

valve clearance in the engine (Figure 4.6).

Important: If feeling uncomfortable about doing

this procedure or the proper tools are not available,

please contact the Authorized Dealer for service

assistance. This is a very important step to insure

longest life for the engine.

To adjust valve clearance:

• Make sure the engine is at room temperature

(between 60° and 80° F).

• Make sure that the spark plug(s) are removed.

• Remove the four screws attaching the valve cover

with a #2 or #3 phillips screwdriver.

• Make sure the piston is at Top Dead Center (TDC)

of its compression stroke (both valves closed). To

get the piston at TDC, remove the screen at the top

of the intake scroll to gain access to the intake fan.

Rotate the engine by hand by rotating the fan while

watching the piston through the spark plug hole.

The piston should move back and forth. The pis-

ton is at TDC when it is as forward as it can go.

• Loosen the rocker jam nut. Use an 10mm allen

wrench to turn the pivot ball stud while checking

clearance between the rocker arm and the valve

stem with a feeler gauge. Correct clearance is

0.002-0.004 inch (0.05-0.1 mm).

NOTE:

Hold the rocker arm jam nut in place as the pivot

ball stud is turned.

When valve clearance is correct, hold the pivot ball

stud in place with the allen wrench and tighten the

rocker arm jam nut. Tighten the jam nut to 174

in.lbs. torque. After tightening the jam nut, recheck

valve clearance to make sure it did not change.

Figure 4.6 - Valve Clearance Adjustment

Valve Stem

Jam Nut

Rocker Arm

Pivot Ball Stud

• Install new valve cover gasket.

• Re-attach the valve cover.

NOTE:

Start all four screws before tightening or it will not

be possible to get all the screws in place. Make

sure the valve cover gasket is in place.

• Re-attach the spark plug wire to the spark plug.

• Repeat the process for the other cylinder.

4.9 COOLING SYSTEM

Air inlet and outlet openings in the generator com-

partment must be open and unobstructed for con-

tinued proper operation. This includes such obstruc-

tions as high grass, weeds, brush, leaves and snow.

Without sufficient cooling and ventilating air flow, the

engine/generator quickly overheats, which causes it

to quickly shut down. (See Figure 4.7 for vent loca-

tions.)



The exhaust from this product gets extremely

hot and remains hot after shutdown. High grass,

weeds, brush, leaves, etc. must remain clear of

the exhaust. Such materials may ignite and burn

from the heat of the exhaust system.

Figure 4.7 – Cooling Vent Locations

AIR

TLE



The maximum ambient temperature for the gen-

erator is 40° C (104° F).

4.10 ATTENTION AFTER SUBMERSION

If the generator has been submerged in water,

it MUST NOT be started and operated. Following any

submersion in water, have an Authorized Dealer thor-

oughly clean and dry the generator.

4.11 CORROSION PROTECTION

Periodically wash and wax the enclosure using auto-

motive type products. Frequent washing is recom-

mended in salt water/coastal areas. Spray engine

linkages with a light oil such as WD-40

4.12 OUT OF SERVICE PROCEDURE

4.12.1 REMOVAL FROM SERVICE

If the generator cannot be exercised every seven days,

and will be out of service longer than 90 days, pre-

pare the generator for storage as follows:

1. Start the engine and let it warm up.

2. Close the fuel shutoff valve in the fuel supply line

and allow the unit to shut down.

3. Once the unit has shut down, it will signal a low

oil fault.

4. Set the AUTO/OFF/MANUAL switch to OFF and

turn off the utility power to the transfer switch.

Remove the 7.5A and 15A fuses from the genera-

tor control panel. Disconnect the battery cables

as outlined in “General Hazards” (page 2).

5. While the engine is still warm from running,

drain the oil completely. Refill the crankcase with

oil. See ”Engine Oil Recommendations,” Section

4.3.1.

6. Attach a tag to the engine indicating the viscosity

and classification of the oil in the crankcase.



Section 4 — Maintenance

Air-cooled 11 kW Generators

Overhead View

7. Remove the spark plug(s) and spray fogging

agent into the spark plug(s) threaded openings.

Reinstall and tighten the spark plug(s).

8. Remove the battery and store it in a cool, dry

room on a wooden board. Never store the battery

on any concrete or earthen floor.

9. Clean and wipe the entire generator.

4.12.2 RETURN TO SERVICE

To return the unit to service after storage, proceed

as follows:

1. Verify that utility power is turned off and that the

AUTO/OFF/MANUAL switch is set to OFF.

2. Check the tag on the engine for oil viscosity and

classification. Verify that the correct recommend-

ed oil is used in the engine (see Section 4.3.1). If

necessary, drain and refill with the proper oil.

3. Check the state of the battery. Fill all cells of

unsealed batteries to the proper level with dis-

tilled water. DO NOT USE TAP WATER IN THE

BATTERY. Recharge the battery to 100 percent

state of charge, or, if defective, replace the battery.

See “Specifications,” Section 1.6, for type and

size.



4. Clean and wipe the entire generator.

5. Remove the 7.5A and 15A fuses from the genera-

tor control panel. Reconnect the battery. Observe

battery polarity. Damage may occur if the battery

is connected incorrectly.

6. Open the fuel shutoff valve.

7. Insert the 7.5A and 15A fuses into the generator

control panel. Start the unit by moving the AUTO/

OFF/MANUAL switch to MANUAL. Allow the unit

to warm up thoroughly.

8. Stop the unit by setting the AUTO/OFF/MANUAL

switch to OFF.

9. Turn on the utility power to the transfer switch.

10. Set the AUTO/OFF/MANUAL switch to AUTO.

11. The generator is now ready for service.

NOTE:

If the battery was dead or disconnected, the exer-

cise timer must be reset.

Section 4 — Maintenance

Air-cooled 11 kW Generators

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Generac Power Systems 004916-0 User manual

Brand: Generac Power Systems

Model: 004916-0

Category: Power generators

Type: User manual

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Quietsource 004916-0

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Generac Power Systems 004916-0 User manual

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